Apparatus and method for applying paint with roller coaters, preferable to photovoltaic panels

ABSTRACT

Roller coater (1) for applying paint to mainly flat panels (8), comprising, in the direction of conveying of panels:a feed roller (9), preferably coupled to a contrast roller (39);an application head for applying paint, comprising an applying roller (3) and a dosing roller (11), said applying roller being preferably coupled to a contrast roller (33);a conveyor (12) for the panels (8) to be painted, preferably in the form of a closed belt conveyor;characterized in thatsaid applying head (9) is covered by its own cover (5),said application head is covered by a preferably vertical cover (2) and a preferably horizontal cover (6), which covers are removable,said applying roller being rotatably mounted on rotation supports (15) placed at its two ends, which are disengageable from said applying roller, said applying roller being withdrawable from its working position and distanceable from said working position in the application head through a withdrawing path providing an initial translation for disengaging it from its rotation supports in the direction of the feed roller (9) and a successive translation in a lifting direction, i.e. distancing it from said conveyor (12), there being provided a lifting member of said roller, preferably coupleable to the ends of said applying roller,the interaxis distance between said feed roller (9) and said applying roller (3) is at least equal to the length of the initial translation path for disengaging the applying roller from the rotational supports (15), and lower to the minimal length of the panels paintable with said roller coater (1).

The present invention relates to an apparatus and a method for applying paint through roller coaters to mainly flat panels. In particular, said apparatus provides for the replacement of the applying roller in said apparatus. In the case of solar (photovoltaic) panels said mainly flat panels are glass panes. Moreover, said apparatus and method allow the precise measuring of the thickness of said glass panes or anyway of the panels painted through said roller coater, and to adjust the application head to the thickness measured for each panel or pane.

Mainly flat panels means panels wherein two of the three dimensions are bigger than the third dimension, by at least one order of magnitude. Typically, the measures of said glass panes are 600×600×1.5 mm to 2000×1400×3 mm.

Typically, an apparatus for applying paint on products using the roller technology is provided with a conveying system, on which panels to be painted are laying. The panels are brought near the application head, made of two rollers: a first chromed dosing roller and a second rubber applying roller. A pump withdraws paint from a tank, and paint is conveyed to a tank formed by said pair of rollers, which are pressurized.

The transposition of paint from the applying roller onto the panel occurs through pressure. The quantity of paint is adjusted through the variation of the pressure applied on the applying roller by the dosing roller. Advantageously, a load cell system can be used, measuring the thrust force of the dosing roller onto the applying roller.

In the art, using reading bars is known in order to detect the actual measures of said panels to be painted, in particular their thickness.

One of the documents of the known art is e.g. U.S. Pat. Nos. 9,314,811B1 of Enid Tech Inc. disclosing an apparatus for applying a sol-gel coating on solar panels. Said apparatus comprises an applying station for applying a coating through rollers, and a station for the jellification of the applied coating.

The apparatuses for painting solar panels on the market are affected by the recurring problem of replacing the applying roller. It is known that the application of paint on such panels requires a high precision of both the quantity and the uniformity of the applied paint layer.

To this aim, a special applying roller must be used, which is lined with a polyurethane elastomer, provided with a finely rectified surface, which is easily damaged. Therefore, the applying roller must be often replaced in order to work and produce with the indispensable quality. In addition to the normal wear, said applying roller enters into contact with the sharp edges of glass panes, which can easily damage it.

On the market there are provided apparatuses of this kind, but due to their built none of the existing apparatuses can allow a fast replacement of the applying roller without the removal of the covers needed to protect human operators from the dangerous contact with the different rotating mechanical parts. In fact, in order to accelerate maintenance times, during the replacement of the applying roller, many of the machines available on the market expose dangerous rotating mechanical parts in order to avoid the time-consuming removal of protective covers.

Moreover, it is known that the glass panes to be painted can be provided with a thickness slightly different on their external sides, i.e. the sides parallel to the conveying direction (left and right side). E.g., a glass pane can be 3 mm thick on the right side and 2.8 mm thick on the left side: this difference can prevent the precise application of paint.

Devices for measuring the thickness of glass panes are known; e.g. using a small roller placed at the entry of the application head is known. Nonetheless, such device is affected by some drawbacks.

The detrimental effect linked to the rolling of the small roller on the glass surface must be accounted for, which introduces measuring mistakes due to concentricity and hopping. Moreover, as said small roller works leaning on the top surface of the glass pane, which is conveyed by the conveying belt, deformations both of the glass pane and of the conveying belt can make such measuring imprecise and unsteady.

Aim of the present invention is providing an apparatus and a fast and cheap method for the replacing of applying rollers, allowing human operators to work safely on the roller coater.

A further aim of the present invention is providing an apparatus and a method for precisely measuring the thickness of said glass panes, allowing an easy and fast adjusting of the position of the application head with respect to the single glass pane.

This object is achieved by an apparatus and a method having the features of the independent claims. Advantageous embodiments and refinements are specified in claims dependent thereon.

The apparatus according to the present invention comprises an applying roller supported by suitable lifting systems, which roller can be lifted without touching any mechanical part and without the need for removing further covers. Said lifting must occur during downtimes, when the roller coater is not applying paint.

In the apparatus according to the present invention, the rotating systems are protected through protective and guarded covers, so that dangerous parts cannot be reached, with the exception of the adjusting organs needed for adjustments. A multifunctional Programmable Logic Controller (PLC) provided with a display allows to adjust and control all the working parameters.

In a second, more sophisticated embodiment, the apparatus comprises a bridge device, in its turn comprising two measuring systems of the thickness of the glass pane to be measured. The apparatus according to this second embodiment is provided with two measuring systems, one on each external side (i.e. right and left side) of the glass pane mounted on said bridge support, which is an accessory of the roller coater. Said bridge device can be placed in different points of the production line with the aim of measuring the thickness of the glass panes and adjusting the inclination of the application head to the specific glass pane to be painted. Obviously, said bridge device must be placed upstream the roller coater, preferably in its immediate proximity. Said bridge device comprises two measuring devices, provided with centesimal precision, which can be moved along the width of the glass pane in order to adjust the measuring system to the different widths of said glass panes. The bridge device is provided with suitable photocell systems for managing suitable automation. Obviously, this entails the painting of a painting batch wherein al the glass panes are provided with the same width.

In this second embodiment, in addition to the measuring bridge device, there is provided also a system for adjusting the application head divided into a control part and a transmission part, provided with two independent motoring managed by brushless motors and movements on ball recirculating runners, capable of reaching centesimal precision in their positioning.

In this way, the transversal position of the application head can be adjusted in the direction of the width to the single glass pane to be painted, in order to adjust it to the difference of thickness on the two sides of the single glass pane.

A first advantage of the present invention consists in the fast replacement of the applying roller, while preserving the safety of human operators. Of course, the replacement must occur during downtimes: the fast replacement allows the shortening of said downtimes.

A second advantage of the present invention is linked to the fact that the roller coater works with a perfectly efficient applying roller, so that glass panes can be perfectly painted, preventing the production of nonconforming products.

A third advantage, linked to the second embodiment measuring the thickness of said glass pane, is the possibility of applying a perfectly uniform layer of paint on all glass panes, even if said glass pane is provided with a non-uniform thickness.

Further advantages and properties of the present invention are disclosed in the following description, in which exemplary embodiments of the present invention are explained in detail on the basis of the drawings:

FIG. 1 Axonometric view of the apparatus with cover;

FIG. 2 Axonometric view of the apparatus, wherein a cover was removed, and applying roller in its working position;

FIG. 3 Lateral view of the apparatus, wherein a cover was removed, and applying roller in the extraction position;

FIG. 4 Lateral view of the apparatus without covers;

FIG. 5 Lateral view of the supporting system for rollers;

FIG. 6 Front view of the lifting system for the applying roller;

FIG. 7 Axonometric view of a detail of the supporting system for the applying roller;

FIG. 8 Axonometric view of the roller coater provided with a bridge device for measuring panels thickness;

FIG. 9 Axonometric view of the bridge device and a conveyor.

It is worth remembering that, although the present description refers to the painting of glass panes, the description can be applied to the painting of panels made of any kind of material.

It is also worth remembering that the roller coater indicated with the numeral 1 is generally a component of a more complex painting line, comprising other sundry (not shown) apparatuses placed upstream and downstream said roller coater 1. E.g., upstream said apparatus 1 there can be provided apparatuses for the pre-treatment of panels, while downstream there can be provided further apparatuses for applying further paint layers and/or ovens for drying/polymerizing the applied paint.

FIG. 1 shows a roller coater 1 provided with the covers needed for its functioning without risk for human operators, as prescribed by the Machinery Directive 2006/42/CE. The bold arrow shows the conveying direction of the glass panes to be painted. In particular, the roller coater 1 is provided with a cover 2 that is to be removed in order to reach an applying roller 3. For safety reasons, the cover is screwed with two screws to said roller coater 1, screws that can be removed through an ordinary tool. Normally said roller coater 1 is provided with a PLC 27 having an interface that allows a human operator both to modify the set-up of the apparatus, and to detect the working parameters of said roller coater 1.

FIG. 2 shows the roller coater 1, wherein said cover 2 was removed and the applying roller 3 in its working position. Said vertical cover 2 covers the applying roller 3. A horizontal cover 6 covers both the applying roller 3 and a dosing roller 11 (visible in FIG. 4). Said applying roller 3 and said dosing roller 11 form an application head.

The dosing roller 11 rotates in the conveying direction of the glass pane 8 (visible in FIG. 8). The applying roller 3 is a reverse roller, i.e. rotates in the opposite direction with respect to the conveying of the panes to be painted, and would tend to repel the glass pane, i.e. send it back to its place of origin.

In order to prevent this, in the art using a feed roller 9 is known (visible in FIG. 4), which rotates according to the conveying direction of the panes, and therefore provides for the conveying of the glass pane 8. A further cover 5 covers said feed roller 9.

It is worth mentioning that the interaxis between said feed roller 9 and the applying roller 3 must be shorter than the minimum length of the shortest glass panel that can be coated in said roller coater. In this case, the distance is 600 mm.

FIG. 3 shows a lateral view of said roller coater 1, while said applying roller 3 is extracted through two straps 4, each placed at one of its two ends. Said straps 4 are part of a lifting member, suitable for the weight of said roller 3, which is around 200 kg. Said lifting member can be a bridge crane or a stacker, placed in a suitable point; the lifting member is independent from said roller coater 1. Said lifting member is used also for inserting a new applying roller 3 into said roller coater 1, in order to replace said worn/damaged roller 3. Obviously, the roller 3 can be replaced only when said roller coater is stopped (during downtimes).

The positions of the rollers and of the covers of the roller coater 1 must be such, that the applying roller 3 can be extracted without entering into contact with other mechanical parts of the coater 1.

The dosing roller 11 undergoes a markedly lesser wear with respect to the applying roller 3. When the dosing roller 11 must be replaced, the top cover 6 is removed, which opens like a door through a hinge 7 placed at the end of said cover 6 oriented to the entry of said panes.

FIG. 4 shows a lateral view of the roller coater 1, wherein the covers 2, 5 and 6 were removed. Said removal allows to observe the feed roller 9, which in use is hidden by said cover 5, the applying roller 3 and the dosing roller 11, which together form the application head, in use hidden by said cover 6. For comparison, the roller indicated with the numeral 3′ shows the position for the vertical extraction of said roller 3. In other words, the roller indicated with 3′ is in the extraction position shown in FIG. 3.

As customary in the art, the feed roller 9 rotates in the conveying direction of the glass panes, and is coupled to a contrast roller 39. The applying roller 3 is a reverse roller and rotates in the direction opposite to the conveying direction. The dosing roller 11 rotates in the conveying direction.

FIG. 4 allows to observe also a closed belt conveyor 12, which is a component of the roller coater 1. Said conveyor 12 is rectified; as customary, the closed belt rotates around two rollers, the first of which is an idle roller 31, while the second roller is a motorized roller 32.

As explained, the applying roller 3 is a reverse roller, i.e. tends to repel the glass pane 8, therefore there must be provided said feed roller 9, which forces the pane across the applying roller 3 and the contrast roller 33. The contrast roller 33 can be moved in the conveying direction, so that when it is moved from the vertical position with respect to the applying roller 3, a too violent contact with the entry edge of the glass pane 8 is prevented.

The conveying belt 12 is rectified in order to prevent surface bulging, due e.g. to a vulcanized joint, so as to prevent thickness differences along the belt. In fact, said differences in thickness provoke a difference of pressure of the applying roller 3, and therefore a difference in the thickness of applied paint.

The feed roller 9 presses on the glass pane 8 with an interference of about 0.5 mm. The glass pane 8 is intercepted by a photocell at the entry of the roller coater 1, which accompanies it until said pane is held between said applying roller 3 and contrast roller 33, with an interference of 0.5 mm again. The feed roller lifts from the glass pane 8 and the pane is dragged by the belt, in order to prevent vibrations during paint application.

FIG. 5 shows a lateral view wherein all the covers were removed, and the support systems of said rollers are shown. Said application head, comprising applying roller 3 and dosing roller 11, moves with respect to the conveying belt 12 through two independent systems 13 provided with ball recirculating runners, one system on the right side and one system on the left side. In this way, it can adjust to the actual dimensions of the thickness of the glass pane 8, which can be different on the two sides for some tenths of millimetre. The motorization is provided with brushless motors and encoder for the detection of position, with a centesimal precision.

The feed roller 9 is provided with a similar lifting system, but without independent adjustment to the thickness on its two sides.

As customary in roller coaters, the dosing of paint occurs through the pressure exerted by the dosing roller 11 on the applying roller 3; a stronger pressure decreases the quantity of applied paint. The speed of transport, too, affects the applied quantity in an unwanted way: in fact, a greater speed of the glass panes 8 generally causes an increase of the quantity of applied paint.

In roller coaters, typically the system for adjusting the quantity of applied paint occurs by varying the pressure applied to said dosing roller 11. On some roller coaters, the dosing roller rotates in reverse, i.e. opposite to the conveying direction, and this leads to a removing of paint from said roller, altering the adjustment of the dosing roller; both can influence the quantity of applied paint.

FIG. 6 shows the lifting member of the applying roller 3 for its replacement. As already explained, said lifting member can be a bridge crane or a stacker suitably placed above said roller coater 1. The lifting member is independent from said roller coater 1.

FIG. 7 shows a detail of the support for the applying roller 3. When in its working position, said applying roller 3 is held by suitable supports 15 that fix the ball bearings on which it rotates. When the applying roller 3 is replaced, said supports are unscrewed through screws 16 and said roller 3 slides, supported by suitable supports of the roller coater 1 in a position suitable for its lifting. In particular, FIG. 7 shows a bracket 14 which aims to prevent the fall of the roller 3 once its supports are removed.

FIG. 8 and FIG. 9 show the second embodiment of the present invention, in particular a bridge device 20 for measuring the thickness of glass panes 8. The two Figures show the preferred placement for the bridge device 20, i.e. upstream a closed belt conveying system 10 placed upstream said roller coater 1.

FIG. 8 shows a glass pane 8 that is inserted into the roller coater 1 through a closed belt conveyor 10 placed upstream said roller coater 1. The bold arrow shows the conveying direction of the glass panes 8.

Upstream said closed belt conveyor 10 there is provided a bridge device 20 according to the second embodiment of the present invention. Said bridge device allows to measure the thickness of glass panes 8 during their conveyance through said bridge device, so that the data are sent in real time to the roller coater 1, which adapts to the transmitted measures.

FIG. 9 shows an axonometric view of said bridge device 20, placed in proximity of the closed belt conveyor 10. The bold arrow shows the conveying direction of the glass panes 8.

Said bridge device 20 comprises:

-   -   A frame 21 provide with feet 22 for fixing it to the floor, so         that the bridge device 20 is independent and can be placed in         the most suitable points of the painting line. In this way,         bumps and/or vibrations generated by the movement of the         rotating organs are prevented, which might affect the precision         of measuring;     -   Supports 23 supporting contact sensors; said supports can be         slid in a direction which is perpendicular to the conveying         direction of the panes 8 to be painted, in order to adapt their         position to the transversal measure (width) of the glass pane 8;     -   Contact sensors 24 (one for each side of the glass); said sensor         24 are divided into two parts, a top part and a bottom part with         respect to the surface of the glass pane 8, and are both         provided with a pneumatic cylinder, in its turn integral with an         encoder detecting the displacement while leaning on the surface         through an idle roller;     -   Transversal photocells 25, detecting the position of the glass         pane 8 and its length;     -   Blocking knobs 26 for blocking said supports 23.

In fact, it is known that glass panes, especially when provided with a low thickness, are not provided with the same thickness on their right and left side, i.e. the sides parallel to the conveying direction of said panes 8. Said difference can be of some tenths of millimetre. As the application of paint on glasses, always destined to solar sector, is particularly delicate and requires an extreme precision, the working pressure of the applying roller 3 on the surface of the glass pane is very important for ensuring the uniformity of the paint layer.

Advantageously, the bridge device 20 is not a component of the roller coater 1 and is fixed to the floor, preventing problems due to vibrations of the roller coater 1 during measuring.

In this second embodiment, although the bridge device 20 is independent from the roller coater 1, nonetheless there is provided a communication system between the bridge device 20 and the PLC 27 of the roller coater 1, allowing to transmit the actual thickness data of each pane 8 to the application head of the roller coater 1 in real time.

Thanks to the use of the bridge device 20, the transversal position of the application head in the direction of width can be adjusted to the actual shape of the pane to be painted, in order to adapt it to the thickness difference between the two sides of the pane, using the above explained system with ball recirculating runners and brushless motor.

In short, the measuring of the thickness of glass panes 8 and the consequent painting of the glass panes 8 occurs as follows:

-   -   a. The glass pane 8 conveyed in the painting line is intercepted         by the photocells 25, activating the measuring sensors 24;     -   b. When the glass pane 8 detected by the photocells reaches the         two sensors 24, said pneumatic cylinders bring said idle roller         in contact with the top and bottom surfaces of the glass pane,         and by value difference the actual thickness of the pane is         measured;     -   c. The measure is transmitted to the PLC 27 of the roller coater         1, which manages the positioning of the application head;     -   d. Through two independent motorizations for positioning each of         the two sides of the roller 3, said roller can be adjusted to         the actual thickness of the glass pane, and with the working         pressure optimal for a correct paint application on both sides;     -   e. When the photocells 25 detect the end of the glass pane, they         send a signal to the measuring sensors 24, which deactivate.

The above description refers specifically to the use of said bridge device 20 for measuring the thickness of glass panes 8 inside a roller painting line for photovoltaic panels. The skilled man cannot miss the fact that any kind of mainly flat panel 8 can be painted in a line comprising the roller coater 1 according to the present invention, e.g. panels made of wood, plastics, fibrocement, etc. Similarly, the skilled man cannot miss the fact that the bridge device 20 according to the present invention can be used in a production line comprising machines of any type working in contact with a main surface of said panel 8, e.g. machines for cleaning said main surface, or sanding machines.

-   1 roller coater -   2 cover -   3 applying roller -   4 strap -   5 cover for the feed roller -   6 cover -   7 hinge -   8 glass pane -   9 feed roller -   10 closed belt conveyor -   11 dosing roller -   12 rectified conveyor -   13 ball recirculating runners system -   14 bracket -   15 support for the applying roller -   16 screw -   20 bridge device -   21 frame -   22 feet for fixing to floor -   23 supports for measuring sensors -   24 contact sensors -   25 transversal photocell -   26 blocking knob -   27 PLC -   31 idle roller -   32 motorized roller -   33 contrast roller -   39 contrast roller 

1. Roller coater (1) for applying paint to mainly flat panels (8), comprising, in the direction of conveying of panels: a feed roller (9), preferably coupled to a contrast roller (39); an application head for applying paint, comprising an applying roller (3) and a dosing roller (11), said applying roller being preferably coupled to a contrast roller (33); a conveyor (12) for the panels (8) to be painted, preferably in the form of a closed belt conveyor; characterized in that said applying head (9) is covered by its own cover (5), said application head is covered by a preferably vertical cover (2) and a preferably horizontal cover (6), which covers are removable, said applying roller being rotatably mounted on rotation supports (15) placed at its two ends, which are disengageable from said applying roller, said applying roller being withdrawable from its working position and distanceable from said working position in the application head through a withdrawing path providing an initial translation for disengaging it from its rotation supports in the direction of the feed roller (9) and a successive translation in a lifting direction, i.e. distancing it from said conveyor (12), there being provided a lifting member of said roller, preferably coupleable to the ends of said applying roller, the interaxis distance between said feed roller (9) and said applying roller (3) is at least equal to the length of the initial translation path for disengaging the applying roller from the rotational supports (15), and lower to the minimal length of the panels paintable with said roller coater (1).
 2. Roller coater (1) for applying paint to mainly flat panels (8) according to claim 1, wherein said vertical cover (2) is provided on the side of the applying roller (3) oriented toward the feed roller (9), and optionally also toward the top side of said applying roller (3) for a given extension in its radial direction, while said applying roller (3) is extracted after having removed said vertical cover (2) only, there being provided a guide for the horizontal translation in the direction of the feed roller (9), provided with end of stroke stops in the terminal position of said initial translation tract toward said feed roll, the applying roller (3) being extracted with two straps (4) coupleable each at an end of said applying roller (3), which is lifted in the vertical direction, preferably through a bridge crane or a stacker.
 3. Roller coater (1) for applying paint to mainly flat panels (8) according to claim 1 or 2, wherein said applying roller (3) is held in its working position by supports (15) which fix the ball bearing on which it turns, which ball bearings are provided on coaxial terminal sections of the shaft of the applying roller, which supports are housings of said ball bearing that can be opened and closed against said ball bearings, comprising at least two lockable portions that are separable along a vertical plane.
 4. Roller coater (1) for applying paint to mainly flat panels (8) according to claims 1-3, wherein said guides for the initial translation of the applying roller (3) toward the feed roller (9) are a couple of brackets (14), each associated to an end of the applying roller and provided coinciding with the terminal section of its shaft, which brackets are provided with an end of stroke tooth at their end oriented toward the feed roller, which brackets are aligned with the respective support of the ball bearing, so that when said applying roller (3) is freed from the supports (15) keeping it in its working position, said applying roller (3) glides, optionally automatically, in a direction opposite to the conveying direction of panels (8), in a position suitable for being lifted upwards, while being supported by said brackets (14).
 5. Roller coater (1) for applying paint to mainly flat panels (8) according to claim 1, wherein said feed roller (9) and said dosing roller (11) rotate in the conveying direction of panels (8), while said applying roller (3) is a reverse roller, i.e. rotates in the direction opposite to the conveying direction of panels (8).
 6. Roller coater (1) for applying paint to mainly flat panels (8) according to claim 1, wherein said roller coater (1) is provided with a PLC (27) adjusting the position of the application head for applying paint with respect to the position of the panel (8) and/or the conveying plane of said conveyor (12), according to the measurement of the actual thickness of the single panel (8) measured by a measuring system, said roller coater (1) being provided with a system for adjusting the position of the application head according to measurement of each panel.
 7. Roller coater (1) for applying paint to mainly flat panels (8) according to claim 6, wherein said system for adjusting the positioning of the application head comprises two independent motorizations, one for the right side and one for the left side of said panel, managed by brushless motors and movements on ball recirculating runners, capable of reaching a centesimal precision in the positioning of the application head, said movements being provided for the mobile support of the application head with respect to the conveyor (12), perpendicularly to its conveying plane.
 8. Roller coater (1) for applying paint to mainly flat panels (8) according to any of the preceding claims, wherein said panels are glass panes, preferably for the production of photovoltaic panels.
 9. Method for roller coating mainly flat panels (8) making use of the roller coater (1) according to claims 1-8, characterized by the following steps: a. Feeding a panel (8) in the painting line; b. Measuring the thickness of each panel (8) through a measuring system; c. Transmitting said measurement to the PLC (27) of said roller coater (1) managing the positioning of the application head; d. Adjusting, through two independent motoring, the positioning of each side of the application head according to the actual thickness value for each measured panel (8). 